JP6811035B2 - Systems and methods for manufacturing reinforced composite structures - Google Patents

Description

The present disclosure relates broadly to the manufacture of composite structures, and in particular to systems and methods of manufacturing reinforced composite structures.

Certain types of composite structures include reinforcing elements to improve the strength and stiffness properties of the composite structure. For example, aircraft wings may include composite skin panels that can be reinforced with composite reinforcements. The composite stiffener is placed inside the composite skin panel and can increase the out-of-plane flexural rigidity of the composite blade skin.

Conventional methods of forming a reinforced composite skin panel may include laying up a composite ply on a skin layup tool to form an uncured composite skin. One or more composite stiffeners can then be individually laid up or mounted on the composite skin. The composite assembly is vacuum bagged and consolidation pressure can be applied to reduce the weight of the composite assembly. Heat is also applied to cure the composite assembly, defining the surface finish of the outer mold line of the composite skin. Unfortunately, the conventional method of laying up composite skins and then installing composite reinforcements individually results in a relatively long process flow time to produce the reinforced composite skin panels.

In an attempt to reduce process flow time, composite stiffeners may be individually laid up on the stiffener tooling to form stiffener assemblies. The skin layup tool, including the uncured composite skin, is attached to the reinforcement assembly to form the skin reinforcement assembly, which is vacuum-bagged and placed in an oven or autoclave for curing. Produces a reinforced composite skin panel. Unfortunately, installing the composite skin on the reinforcement assembly requires the use of a crane to lift and place the skin layup tool, which precisely turns the composite skin into a composite reinforcement. In addition to the difficulties in aligning, it can bring difficulties in maintaining the safety of the workplace.

In addition, the skin layup tool must be relatively rigid so as not to distort the contours of the outer mold lines on the layup surface during the layup of the composite skin. Unfortunately, relatively rigid skin layup tools can present difficulties in applying uniform consolidation pressure to the composite skin during weight loss. In addition, relatively rigid skin layup tools have a relatively large mass, which can result in the application of excessive consolidation pressure to the composite skin, composite reinforcement, and reinforcement tooling. In addition, the relatively large mass of the rigid skin layup tool increases the amount of time required to heat the composite assembly to cure temperature and cool it to ambient temperature after the composite assembly has been cured. I can let you.

As can be understood, the art requires a crane to allow layup of composite skin in parallel with layup of composite reinforcement, and to lift and place skin layup tools. Without, there is a need for systems and methods for producing reinforced composite skin panels that allow the application of uniform consolidation pressure to the composite skin during weight loss.

The above-mentioned needs associated with the manufacture of integrally reinforced composite structures include stiffener tooling assemblies, backing plates, and rotatable strong backs detachably connected to backing plates. Provided with the system, this disclosure specifically addresses and mitigates. Reinforcement tooling assemblies are configured to support multiple composite reinforcements. The backing plate may have a layup surface for laying up the composite skin. The strong back can be detachably connected to the backing plate. The system may further include multiple hinges, each having a fixed hinge portion and a movable hinge portion. The fixed hinge portion can be connected to a fixed object such as the floor of the work site of the manufacturing facility. The movable hinge portion may be connected to the strongback such that the strongback rotates between the open and closed positions due to the engagement of the backing plate reinforcement tooling assembly. In one embodiment, the system may include multiple linear actuators located on the side of the strongback opposite the hinge when the strongback is in the closed position. The post and hinge linear actuators operate in a coordinated manner to lower the strongback and backing plate vertically from the hover position to the docked position, whereby the composite skin is It may be placed in contact with the composite reinforcement.

Also disclosed are methods for manufacturing reinforced composite skin panels. The method may include providing a backing plate that includes a layup surface that supports a composite skin. The method may further include providing a composite stiffener assembly that includes one or more composite stiffeners laid up on the stiffener tooling. Further, the method may include detachably connecting the strongback to one of a backing plate and a stiffener tooling assembly using a plurality of hinges, each having a fixed hinge portion and a movable hinge portion. , The fixed hinge portion can be connected to a fixed object. The movable hinge portion can be connected to a strong back. The method is coupled from an open position to a closed position to one of a backing plate and a reinforcing material tooling assembly in order to engage the composite skin with the composite reinforcement to form a reinforced composite skin panel. It may include rotating a strong back.

The features, functions, and advantages described herein can be achieved independently in various embodiments of the present disclosure, or further details can be understood with reference to the following description and drawings. , And may be combined in still other embodiments.

These and other features of the present disclosure will become clearer with reference to the drawings. In the drawings, similar reference numbers refer to similar parts throughout.

It is a block diagram of an Example of a system for manufacturing a reinforced composite outer panel. FIG. 3 is a perspective view of an aircraft with wings formed from one or more reinforced composite skin panels. It is a top view of the outer panel of a wing configured as a reinforced composite outer panel including a composite outer panel and a plurality of composite reinforcing materials. It is a side view of the reinforced composite outer panel of FIG. It is an end view of the reinforced composite outer panel of FIG. It is an enlarged view of a part of an Example of a reinforced composite outer panel having a composite outer panel and a plurality of composite reinforcing members. It is an exploded view of a part of a reinforced composite outer panel. Manufactures reinforced composite skin panels, including a backing plate that is detachably connected to a strong back that can rotate between open and closed positions to engage the composite skin with multiple composite reinforcements. It is a perspective view of one Example of the system for this. It is a top view of the system of FIG. It is a bottom view of the system of FIG. It is an exploded view of a backing plate and a strong back. It is a perspective view of the back side of the back plate which shows the framework for supporting the layup surface of the back plate. It is a perspective view of an Example of a socket type fixture attached to a backing plate as a part of an index mechanism for positioning or aligning a backing plate with a strong back. It is a perspective view of an Example of a ball type fixture attached to a strong back. It is a perspective view of an Example of a ball-type fixture in which a clamp for fixing a backing plate is incorporated in a strong back. It is a perspective view of the backing plate fixed to a strong back. FIG. 5 is a perspective view of a backing plate and a reinforcing material tooling assembly in an open position, in which the backing plate supports a composite outer plate and the reinforcing material tooling assembly supports a plurality of composite reinforcing materials. It is sectional drawing of one Example of the backing plate supported on the strong back. FIG. 5 is a cross-sectional view of an embodiment of a reinforcing material tooling assembly supported on a bond cart. It is an end view of a backing plate supported on a strong back connected to a hinge. One implementation of a hinge that has a pair of rotary actuators for rotating the movable hinge portion and further includes a linear actuator for vertically moving the backing plate and strongback from the floating position above the reinforcement tooling assembly to the dock position. It is sectional drawing of an example. FIG. 5 is a perspective view of a system showing a backing plate and a strongback during rotation from an open position to a closed position and further showing an alignment system for aligning the backing plate with a stiffener tooling assembly. FIG. 3 is a perspective view of the system showing a backing plate and a strongback in a closed position (eg, floating or docking position). It is a side view of a backing plate and a strong back in a closed position, and shows a linear actuator included in each of a hinge and a post. FIG. 5 is a side view of a post with a linear actuator for supporting at least a portion of the mass of the strongback in the closed position and for vertically lowering the strongback from the floating position to the dock position. Side view of the hinge showing a first rotary actuator and a second rotary actuator for rotating the moving part of the hinge, and further showing a linear actuator included in the hinge for supporting and / or lowering the strongback vertically. Is. FIG. 6 is a schematic of a strongback canceling system including a plurality of linear actuators for supporting the mass of the strongback and for vertically lowering the backing plate from the floating position to the dock position. It is a perspective view of the system which shows the rotation of a strong back from a closed position to an open position after docking a backing plate on a reinforcing material tooling assembly and disconnecting a strong back from a backing plate. It is a perspective view of a strong back in an open position. A backing plate docked to the reinforcement tooling assembly with the strongback removed, and both before loading the assembly into an oven or autoclave for co-curing or co-bonding the composite skin with the composite reinforcement. It is a perspective view of the combined composite outer plate and composite reinforcing material. It is a schematic exploded view of a composite assembly cut along the span direction, and shows the thickness of the composite skin that changes along the chord direction before weight loss. It is the schematic of the composite outer plate and the composite reinforcing material sandwiched between the reinforcing material tooling and the backing plate in order to apply the consolidation pressure to the composite outer plate and the composite reinforcing material for weight loss. In the schematic of the assembly of FIG. 31, showing obedience (eg, out-of-plane flexibility) of the backing plate to accept changespan direction changes in the amount where the stack thickness is reduced as a result of weight loss. is there. FIG. 3 is a perspective view of the system after the strongback has been reattached to the backing plate to allow the backing plate to be removed from the hardened and reinforced composite skin panel. It is a flowchart which includes one or more steps which can be included in the method of manufacturing a reinforced composite outer panel. FIG. 5 is an end view of the system showing a backing plate and reinforcement tooling assembly in an open position. FIG. 3 is an end view of the system showing a backing plate and a strongback during rotation from the open position to the closed position, along with the stiffener tooling assembly. FIG. 5 is an end view of the system showing a backing plate and a strongback in a closed position (eg, floating position). FIG. 3 is an end view of a system showing a backing plate vertically lowered from a floating position to a dock position so that the composite skin engages the composite reinforcement. FIG. 3 is an end view of the system showing a strong back and backing plate in a floating position above the stiffener tooling assembly. FIG. 3 is an end view of the system showing a strong back and backing plate in the dock position, along with a stiffener tooling assembly. FIG. 5 is an end view of the system showing a strongback that has been disconnected from the backing plate and rotated so that it is returned from the closed position to the open position. It is the end view of the system which shows the strong back in an open position.

Now referring to the drawings drawn for the purpose of showing the various embodiments of the present disclosure, FIG. 1 shows an implementation of the system 300 for manufacturing the reinforced composite skin panel 150 (see FIG. 2). An example block diagram is shown. The system 300 may include a reinforcement tooling assembly 480 that includes a reinforcement tooling 482, such as a reinforcement forming block 484, configured to support a plurality of hardened or uncured composite reinforcements 200. In one embodiment, one or more of the composite reinforcements 200 may be formed as a layup of the uncured composite ply 162 (see FIG. 6). The composite ply 162 can be formed from a pre-impregnated fiber reinforced polymer matrix material (prepreg). The stiffener tooling assembly 480 may be supported on a bond cart 486.

Further, the system 300 may include a backing plate 302 that may also function as a layup mandrel 306 having a layup surface 306 configured to lay up the composite skin 152. The layup of the composite skin 152 can be formed as a laminate of uncured composite plies 162. The composite ply 162 can also be a prepreg composite ply. The backing plate 302 is formed as a relatively lightweight structure and is locally obedient during the process of weight loss of the composite outer plate 152 when the backing plate 302 is engaged with the composite stiffener 200. Can be made possible. Further, forming the backing plate 302 as a lightweight structure minimizes the thermal mass of the backing plate 302, which is the co-curing of the composite outer plate 152 to the composite reinforcing material 200. Alternatively, during the co-bonding process, the amount of time required for heating and cooling the backing plate 302 / reinforcing material tooling assembly 480 may be reduced.

The system 300 may further include a strongback 370. The strongback 370 extends along the wingspan direction 154 and / or the chord direction 152 of the backing plate 302 and may be detachably connected to the backing plate 302 by using one or more fixing mechanisms. For example, if multiple clamps 334 are mounted on the backing plate and / or the strongback detachably connects the backside 304 of the backing plate 302 (eg, the opposite side of the layup surface 306) to the strongback 370. , Can be attached to a strong back. The strongback 370 may be formed as a relatively rigid frame or truss structure 372 to increase the overall stiffness of the backing plate 302. In one embodiment, the strongback 370 may be formed from structural steel or other high-strength material and may be configured to support the backing plate 302 during the layup of the composite skin 152. In this regard, the relatively rigid strongback 370 can prevent distortion of the layup surface 306 of the backing plate 302 during the layup of the composite skin 152. In addition, the strongback 370 may support the backing plate 302 during rotation of the backing plate 302 onto the stiffener tooling assembly 480. With the strongback 370 removed from the backing plate 302, the backing plate 302 is locally obedient to facilitate out-of-plane bending of the backing plate 302, of the composite ply 162 forming the composite outer plate 152. Accepts changes along the wingspan and / or chord direction in the amount where the stack thickness 164 is reduced during weight loss and / or during hardening (eg, due to hardening shrinkage).

The system 300 may include one or more hinges 420 for rotating the strongback 370. Each of the hinges 420 may include a fixed hinge portion 430 and a movable hinge portion 440 rotatably interconnected by a hinge pin 426. The fixed hinge portion 430 may be connected to a fixed object 424 such as the floor of the work site. The movable hinge portion 440 may be connected to a strong back 370. The hinge 420 may include one or more rotary actuators 434 for rotating the strongback 370 between the open position 400 (see FIG. 8) and the closed position 402 (see FIG. 23). The system 300 is for supporting the mass of the strongback 370 and / or for lowering the backing plate 302 vertically from the floating position 404 to the dock position 406 once the strongback 370 has been rotated from the open position 400 to the closed position 402. It may also include one or more linear actuators 456. In one embodiment, each of the hinges 420 may include a linear actuator 456 (eg, a z-axis actuator). Further, the system 300 may include one or more posts 452 where one or more may have a linear actuator 456.

The hinge 420 and post 452 linear actuators 456 are operated in a coordinated manner to support the mass of the strongback 370 and float the strongback 370 in a controlled manner, as described in more detail below. Vertically lowered from 404 to dock position 406 to accurately align the composite skin 152 (supported, eg, on the backing plate 302) with the composite reinforcement 200 (supported, eg, on the reinforcement tooling 482). To enable. Once the composite outer plate 152 and the composite stiffener 200 are in contact with each other to form a composite assembly, the strongback 370 can be removed from the backing plate 302 and rotated towards the open position 400 away from the backing plate 302. .. The composite assembly sandwiched between the backing plate 302 and the stiffener tooling is vacuum bagged for weight loss with the backing plate 302 docked to the stiffener tooling assembly 480 and / or of the composite skin 152. It can be moved into an oven or autoclave for co-curing or co-bonding to the composite stiffener 200.

In one embodiment not shown, the strongback 370 is detachably connected or detachably secured to the backing plate 302 for rotation onto the stationary reinforcing material tooling assembly 480 of the backing plate 302 supported by the strongback. Instead, the strongback 370 is detachably connected or detachably secured to the reinforcement tooling assembly 480, allowing the reinforcement tooling assembly 480 supported by the strongback to rotate onto the stationary backing plate 302. To. In this regard, the systems 300 and methods of the present disclosure have been described in the context of the strongback 370 being detachably coupled to the backing plate 302, but the structural components, functions, and process steps described herein. Any one or more of them may be mounted in a configuration in which the strongback 370 is detachably coupled to the stiffener tooling assembly 480.

FIG. 2 is a perspective view of an aircraft 100 that may include one or more composite structures formed from a reinforced composite skin panel 150. Aircraft 100 may include a fuselage 102 having a tail 104 that also includes a horizontal stabilizer 106 and a vertical stabilizer 108, which may also be formed from a reinforced composite skin panel 150. Aircraft 100 may include a pair of main wings 114 and one or more propulsion units 110. For example, the propulsion unit 110 may include an engine nacelle 112 attached to the main wing 114. The wing 114 may include a wing skin that defines the upper and / or lower surfaces of the wing 114 and may be formed as a reinforced composite skin panel 150.

FIG. 3 is a plan view of the wing outer panel configured as the reinforced composite outer panel 150. The wing skin extends from the root portion 116 of the wing to the tip portion 118 and may include the nacelle portion 120 at a position where the engine nacelle 112 is attached to the wing 114. As described below, the wing skin is formed from a composite ply 162 that can be locally increased in a particular region along the wingspan direction 154 of the wing 114, with increased loads at such positions. accept. For example, the root portion 116 may generally have an increased stacking thickness of 164 relative to the tip portion 118. The nacelle portion 120 has an increased stacking thickness 164 relative to the stacking thickness 164 at the root portion 116 and can accept the increased load from the engine nacelle 112.

The reinforced composite skin panel 150 is shown to be oriented parallel to the composite skin 152, and generally parallel to each other, extending from the root 116 to the tip 118 of the blade along the span direction. Can be made up of a plurality of composite stiffeners 200. The composite outer plate 152 can be laid up on the layup surface 306 of the backing plate 302, as described above. Similarly, the composite stiffener 200 may be separately laid up on the stiffener tooling 482. After another layup of the composite skin 152 and the composite reinforcement 200, the composite skin 152 and the composite reinforcement 200 are combined or combined using the rotatable strongback 370 disclosed herein. Can be engaged. Once the composite outer plate 152 is engaged with the composite reinforcing member 200, the strong back 370 is released or disconnected from the backing plate 302, and the strong back 370 is rotated to return to the open position to release the backing plate. It may be left docked to the stiffener tooling assembly 480. The layup surface 306 of the backing plate is a cowl for giving the composite outer plate 152 a surface finish and an outer mold line (OML) contour during co-curing or co-bonding of the composite outer plate 152 with the composite reinforcing material 200. Can be used as a surface.

The systems 300 and methods of the present disclosure are described in the context of composite wing skins integrally reinforced with respect to the aircraft 100, but the systems 300 and methods are, but are not limited to, any transporter or non-transport. It can be implemented to form a composite structure for body applications. In this regard, the system 300 and method are such that the uncured composite skin 152 forms any type of composite structure that is co-cured or co-bonded with the cured or uncured composite stiffener 200. Can be implemented. Further, the system 300 and method can be implemented to combine and co-join the cured composite skin 152 with the uncured composite stiffener 200.

FIG. 4 is a side view of the reinforced composite outer panel 150 of FIG. In the examples shown, the skin panel is shown to have a curved shape extending from the root portion 116 to the tip portion 118. However, the reinforced composite skin panel 150 may have a flat shape and / or a curved shape with undulations along any portion of the skin panel. Further, the curvature can extend along one or more directions, such as the wingspan direction 154 or the chord direction 156.

FIG. 5 is an end view of the reinforced composite outer panel 150 of FIG. 3 showing a plurality of composite reinforcing members 200 formed on the inner mold line 158 of the reinforced composite outer panel 150. The plurality of composite stiffeners 200 are shown to be evenly distributed along the chord direction 156. However, the reinforced composite skin panel 150 may include any number of composite stiffeners 200 that can be uniformly or non-uniformly distributed.

FIG. 6 is an enlarged view of a part of the reinforced composite outer panel 150 of FIG. 5 composed of the composite outer panel 152 and the plurality of composite reinforcing members 200. As shown above, the composite skin 152 and the composite stiffener 200 can be formed from a plurality of composite plies 162. The composite ply 162 can be made up of a plurality of reinforcing fibers (not shown) surrounded by a matrix material (not shown). Reinforcing fibers can be high module or high strength fibers made of carbon, glass, or other fiber material. The fibers in the composite ply are either continuous fibers that can be aligned or oriented together in a single direction (eg, unidirectional fibers) or are woven together in two or more directions within the fiber arrangement (not shown). obtain. As shown above, the composite ply 162 is provided as a pre-impregnated composite ply 162 in which the reinforcing fibers can be pre-impregnated with a polymer matrix material (eg, prepreg) such as a thermosetting resin (eg, epoxy). Can be done. Although not shown, the composite skin 152 may be formed as a sandwich structure with a sandwiched (not shown) core between a pair of composite laminated surface plates (not shown), and the composite ply 162 is solid laminated. It is not limited to being formed as a plate.

FIG. 7 is an exploded view of a portion of the reinforced composite skin panel 150 of FIG. 6 showing the plurality of composite plies 162 that make up the composite skin 152. In the embodiment shown, the composite stiffener 200 is formed by a side-by-side assembly of a plurality of inverted L-shaped composite elements. Each L-shaped composite element may include a flange 206 and a web 204 extending outward from the flange 206. The flanges 206 of the plurality of L-shaped composite elements can be combined with the composite skin so that the flange 206 is in contact with the surface of the inner mold line 158 of the composite skin 152. Adjacent L-shaped composite element webs 204 are arranged back to back with each other to form a plurality of blade sections 202 of the composite stiffener 200. The R-filler 170 may be installed in the notches formed between each adjacent pair of composite stiffeners 200. Although the present disclosure shows the composite reinforcement 200 as a blade section 202, the composite reinforcement 200 may have other cross-sectional shapes, including, but not limited to, a C section, an I section, a hat section, or other shape. Can be formed.

FIG. 8 is a perspective view of an embodiment of the system 300 for manufacturing the reinforced composite skin panel 150. In the embodiments shown, the system 300 is shown at the open position 400 and includes a backing plate 302 where the composite skin 152 can be laid up. The backing plate 302 can be detachably connected to the strong back 370. The strongback 370 may be attached to one or more hinges 420. The hinge 420 facilitates the rotation of the strongback and backing plate between the open position 400 and the closed position 402, and the closed position 402 connects the composite skin 152 to the reinforcing material tooling 482 forming the reinforcing material tooling assembly 480. Positions for engaging with a plurality of composite stiffeners 200 that may be laid up separately on top. As shown above, the stiffener tooling assembly 480 may be supported on a bond cart 486, which may include a truss structure supported on a surface such as the floor of the work site. The system 300 may include one or more posts 452 arranged on the outer circumference of the stiffener tooling assembly 480. One or more of the posts 452 are of the composite outer panel 150 which is to support the mass of the strongback 370 and to vertically lower the backing plate 302 so as to dock-engage with the reinforcing material tooling 482. It may include a linear actuator 456 for vertically raising (eg, undocking) the backing plate 302 from the reinforcement tooling assembly 480 after curing.

FIG. 9 is a top view of the system 300 of FIG. 8 showing a set of four (4) hinges 420 attached to the strongback 370. Each of the hinges 420 may include a fixed hinge portion 430 having a hinge base 422 that can be attached to be fixed to the fixed object 424, such as a work site floor or other immovable surface or object. As shown above, each of the hinges 420 may include a movable hinge portion 440 connected to a fixed hinge portion 430 by a hinge pin 426 defining a hinge shaft 428. The hinge shafts 428 of the plurality of hinges 420 may be aligned with each other (eg, coaxially).

FIG. 10 is a bottom view of the system 300 of FIG. The hinge base 422 includes one or more legs extending laterally outward from the fixed hinge portion 430 and may support the mass of the strongback 370 while rotating between the open position 400 and the closed position 402. .. One or more indexing mechanisms 320 that can be incorporated into the strongback 370 and the backing plate 302 are also shown in FIG. In the embodiments shown, the index mechanism 320 may include discrete engagement points or attachment points between the backing plate 302 and the strongback 370. The index mechanism 320 may be distributed along the wingspan direction 154 and / or the chord direction 156 of the strongback 370 in order to position or align the strongback 370 with the backing plate 302. Further, the index mechanism 320 uniformly supports the mass of the backing plate 302 on the strong back 370 at the open position 400 during the layup of the composite ply 162 for forming the composite outer plate 152. Can function as a load bearing point.

FIG. 11 is an exploded view of the backing plate 302 and the strong back 370. As shown above, the backing plate 302 can be constructed as a relatively lightweight structure. For example, the strongback 370 was configured to support the backing plate 302 during the layup of the composite skin 152 and during the rotation of the backing plate 302 between the open position 400 and the closed position 402. It can be constructed as a relatively rigid frame or truss structure 372. As shown above, the system 300 may incorporate one or more indexing mechanisms 320 to detachably connect the strongback 370 to the backing plate 302.

FIG. 12 is a perspective view of the backing plate 302 showing the back side 304. In the embodiments shown, the backing plate 302 is as a grid or framework 308 of interconnected ribs 310 and / or bulkhead 312 extending along the chord direction 156 and / or the wingspan direction 154. Can be formed. The framework 308 of the ribs 310 and the bulkhead 312 may form a backing structure and support a surface plate defining the layup surface 306 of the backing plate 302. In order to reduce the weight of the backing plate 302, the ribs 310 and / or the bulkhead 312 may be formed as the composite ribs 310 and / or the composite bulkhead 312. Forming the backing plate 302 as a composite structure instead of a conventional metal structure such as Invar can significantly reduce the structural mass and thermal mass of the backing plate 302. However, any portion of the backing plate 302 may be formed from a metal material or a combination of a metal material and a composite material.

As shown above, when the backing plate 302 is attached to the strongback 370, the backing plate 302 is overall (eg, along the wingspan direction 154 and / or along the chord direction 156). It is rigid and can maintain the intended contour of the outer mold line 160 of the layup surface 306 of the backing plate 302. However, when disconnected from the strongback 370, the backing plate 302 is locally obedient in the out-of-plane direction, during the weight loss of the composite skin 152 and / or the composite reinforcement of the composite skin 152. During co-curing or co-bonding with 200, differential changes in the wingspan direction at a stack thickness of 164 can be accepted.

FIG. 13 is a perspective view of an embodiment of the socket type fixture 328 of the index mechanism 320 for positioning or aligning the strong back 370 with the backing plate 302. A similar configuration may be included in an embodiment in which the strongback 370 is engaged with the stiffener tooling assembly 480. In FIG. 13, the socket type fixture 328 may include a socket 332 or a socket plate 330 with a bore. The socket plate 330 may be mechanically secured and / or glued to the backing plate 302, such as one or more of the vertically oriented ribs 310 and / or bulkhead 312 of the backing plate 302. In the embodiments shown, the socket plate 330 may be attached to the backside 304 of the backing plate 302.

FIG. 14 is a perspective view of an embodiment of the ball-type fixture 322 attached to the strong back 370. The ball-type fixture 322 may include a plate 324 having a ball 326 projecting upwards on the plate. The ball 326 may be sized and configured to engage the socket 332 of the socket type fixture 328 that may be mounted on the backing plate 302. The plurality of ball-type fixtures 322 and socket-type fixtures 328 may be attached to the strongback 370 and the backing plate 320, respectively, or vice versa. The plurality of ball-type fixtures 322 and socket-type fixtures 328 are distributed in the wingspan direction 154 and the chord direction 156 of the strong back 370 and the backing plate 302, and guide the backing plate 302 and the strong back 370 to engage with each other. I can let you.

FIG. 15 is a perspective view of an embodiment of the ball-type fixture 322 in which a clamp 334 for fixing the backing plate 302 is incorporated in the strong back 370. Alternatively or additionally, one or more of the socket type fixtures 328 may include a clamp 334 for detachably connecting the strongback 370 to the backing plate 302. The clamp 334 is used when the backing plate 302 is hung from the strongback 370 or supported by the strongback 370, such as while rotating the strongback and backing plate to the closed position 402 or floating position 404 (see FIG. 37). It can be evenly distributed along the strongback 370 to uniformly support the mass of the backing plate 302.

FIG. 16 is a perspective view of the backing plate 302 fixed to the strong back 370. One or more of the clamps 334 may be integrated into one or more of the socket type fixtures 328 and / or the ball type fixtures 322. Each clamp may include a clamp arm 336 configured to engage the underside of plates 324, 330 of the respective ball fixture 322 and / or socket fixture 328. In the embodiments shown, the clamp arm 336 may be pneumatically actuated, but other means for actuating the clamp 334, including but not limited to hydraulic actuation, electromechanical actuation, or other means are implemented. Can be done.

FIG. 17 is a perspective view of the backing plate 302 and the reinforcing material tooling assembly 480 at the open position 400. A backing plate 302 that supports the composite outer plate 152 is shown. The composite stiffener 200 may be laid up separately on the stiffener tooling 482, such as when the stiffener tooling assembly 480 is in the open position 400.

FIG. 18 is a cross-sectional view of an embodiment of the backing plate 302 supported on the strong back 370. The composite outer plate 152 can be formed by laying up a plurality of composite plies 162 in a predetermined ply stacking sequence (not shown) on the layup surface 306 of the backing plate 302. The strongback 370 provides a rigid support structure that can prevent the contours of the layup surface 306 from deforming during the layup process.

FIG. 19 is a cross-sectional view of an embodiment of a reinforcing material tooling assembly supported on a bond cart 486 (represented schematically). The stiffener tooling 482 may include a plurality of stiffener forming blocks 484. In one embodiment, the uncured composite ply 162 can be laid up on the individual stiffener forming blocks 484 to form one or more L-shaped composite elements as shown in FIG. In one embodiment not shown, each of the stiffener forming blocks 484 may be configured to form a pair of L-shaped composite elements, each having a web 204 and a flange 206. After forming the composite ply 162 into an L-shaped composite element on the reinforcing material forming block 484, the reinforcing material forming block 484 is parallel so that the webs 204 of the adjacent L-shaped composite elements come into contact with each other. Can be combined in a parallel arrangement with. When the forming blocks 484 are combined, the flange 206 of the composite stiffener 200 may collectively form a contour that matches the contour of the inner mold line 158 of the composite skin 152 to be engaged with the flange 206. As shown above, the composite reinforcement is shown as a blade section 202 formed as a back-to-back L-shaped composite element, where the composite reinforcement 200 is of a variety of different configurations of the composite element. By combining any one of the above, it may be provided in any one of a variety of different cross-sectional configurations (eg, hat section, C section, I section, etc.).

FIG. 20 is an end view of a backing plate 302 supported on a strong back 370 connected to a hinge 420. One side of the strongback 370 may be supported by one or more hinges 420. The other side of the strongback 370 may be supported by one or more jack stands 382, or other support structures that support the strongback support fitting 380. As shown above, each hinge 420 may have a hinge base 422, a fixed hinge portion 430, and a movable hinge portion 440. The fixed hinge portion 430 may extend upward from the hinge base 422. The fixed hinge portion 430 may include one or more vertically oriented fixed hinge plates 432. In one embodiment, each of the fixed hinge plates 432 may support a hinge pin 426. The movable hinge portion 440 may include one or more movable hinge plates 442. The hinge 420 may further include at least one hinge pin 426 that connects the fixed hinge plate 432 to the movable hinge plate 442 by one or more of the hinge pins 426. In the embodiments shown, each hinge 420 may include a pair of parallel fixed hinge plates 432 extending vertically upward from the hinge base 422. Further, each fixed hinge plate 432 may have a pair of opposed movable hinge plates 442 arranged on both sides of the fixed hinge plate 432 and connected to a hinge pin 426 extending through the fixed hinge plate 432. However, the hinge 420 may be provided in any configuration that provides a fixed hinge portion 430 and a movable hinge portion 440 for rotating the strongback 370.

FIG. 21 is a cross-sectional view of an embodiment of the hinge 420 with some of the hinge plates 432 and 442 removed to show the actuators 434, 436, 438 and 456. The strongback 370 may be connected to one or more of the movable hinge plates 442 using a strongback mounting fitting 376. In the embodiments shown, the strongback mounting fitting 376 may be sized and configured to engage one or more strongback mounting pins 444 that may be included fixed to the movable hinge plate 442. It may include the above engaging grooves or slots 378. The strongback mounting fitting 376 includes a pair of hooks that may have slots 378, such as raising or lowering the strongback 370 vertically to disengage or engage slot 378 with the strongback mounting pin 444, respectively. Allows the strongback 370 to be detachably connected to the fixed hinge plate 432. To maintain engagement of the strongback mounting fitting 376 with the strongback mounting pin 444 during rotation when the strongback mounting fitting 376 is flipped, the hinge 420 attaches the strongback to the strongback mounting pin 444. It may include one or more mechanical stops 458 to prevent the sliding motion of the fitting 376. In the embodiments shown, the mechanical stop 458 may be configured as a lever 462 that can be rotatably attached to one or more of the movable hinge plates 442. Lever 462 may have a termination that can be rotated to a locked position so that the termination withstands at least one of the hooks to prevent movement of the strongback mounting fitting 376 with respect to the strongback mounting pin 444. ..

In FIG. 21, the hinge 420 may include a movable hinge portion 440 and a pair of rotary actuators 434 for rotating a backing plate 302 that may be connected to the strongback 370 and the strongback 370. The hinge 420 is vertical caused by the gravity of the backing plate 302 and the strongback 370 after the lever 462 has been rotated to the unlocked position so that the end of the lever 462 no longer contacts the strongback mounting fitting 376. A linear actuator 456 for controlling movement may also be included. The linear actuator 456 allows vertical movement caused by the gravity of the strongback 370 and the backing plate 302 from the floating position 404 (see FIG. 39) above the reinforcement tooling assembly 480 to the dock position 406 (see FIG. 40). Can be. At dock position 406, the composite skin 152 may come into contact with the composite reinforcement 200 that may be supported on the reinforcement tooling 482. The rotary actuator 434 and / or the linear actuator 456 may be configured as a hydraulic cylinder 464. In one embodiment, one or more of the hinges 420 may include a pair of rotary actuators 434, such as a first rotary actuator 436 and a second rotary actuator 438.

In the embodiment of FIG. 21, rotary actuators 434 (eg, first and second rotary actuators 436, 438) may be placed between the fixed hinge plate 432 and the movable hinge plate 442. However, the rotary actuator 434 may be attached to the outside of one or both of the hinges 420. In the embodiment shown, the lower end of the first rotary actuator 436 and the lower end of the second rotary actuator 438 may be connected to the hinge base 422. The upper end of the first rotary actuator 436 and the upper end of the second rotary actuator 438 may be pinned to one or more of the movable hinge plate 442 of the movable hinge portion 440. In the embodiments shown, the lower ends of the first and second rotary actuators 436 and 438 may be coupled to the hinge base 422. The upper end of the first rotary actuator 436 may be pinned to one or more of the movable hinge plate 442 at a position different from the position where the second rotary actuator 438 is pinned to one or more of the movable hinge plate 442.

In FIG. 21, the first rotary actuator 436 and the second rotary actuator 438 are each configured as dual-acting hydraulic cylinders, meaning that each actuator hinges a strongback 370. It is possible to have the ability to alternately apply pushing and pulling forces to assist in rotating around the shaft 428. For example, while the strongback 370 rotates from the open position 400 to the closed position 402, the first and second rotary actuators 436 and 438, respectively, have a pushing force that prompts the movable hinge plate 442 to rotate upward. Can be stretched to add. At the point where each axis of the first rotary actuator 436 and the second rotary actuator 438 individually (eg, at different times) crosses the hinge axis 428, the first and second rotary actuators 436 and 438 are separate at different times. It is possible to initiate contraction and application of a pushing force to counter the contraction evoked by the downward movement caused by the gravity of the strongback 370. In this regard, the first and second rotary actuators 436 and 438 may be configured to maintain a substantially constant rate of rotation of the strongback 370.

FIG. 22 is a perspective view of the system 300 showing a backing plate 302 and a strongback 370 at a point in the middle of rotation from the open position 400 (see FIG. 17) to the closed position (see FIG. 22). .. In the embodiments shown, the system 300 is configured to align the backing plate 302 with the reinforcement tooling assembly 480 as the two components are moved to dock and engage with each other. It may include at least one alignment mechanism 350. In one embodiment, the alignment mechanism 350 is moved so that the composite skin 152 comes into contact with the composite reinforcement 200 while the strongback 370 and the backing plate 302 are lowered onto the reinforcement tooling assembly 480. A computer-aided measurement (CAM) device, such as a visual system and / or a laser measurement device 352, configured to detect a misalignment of the composite skin 152 with the composite reinforcement 200 may be provided.

In one embodiment, one or more laser measuring devices 352 may first be positioned on the hinge shaft 428 of the hinge 420. One or more of the laser measuring devices 352, such as time-of-flight lasers (not shown), are attached to surrounding structures such as ceilings or walls of buildings, or reinforcement tooling assemblies. It can be attached to 480 or one or more alignment fixtures (not shown) that can be built adjacent to a floor-mounted support or stand (not shown). The alignment mechanism 350 is not limited to one or more laser measuring devices 352, and is optional for detecting the position of one or more optical tooling targets 354 which can be attached to one or more positions on the outer circumference of the reinforcement tooling assembly 480. May include a properly configured alignment device.

In one embodiment, the alignment mechanism 350 (eg, laser measuring device 352) is misaligned or inconsistent between the measured position of the optical tooling target 354 and the desired position of the optical tooling target 354 with respect to the hinge axis 428. The amount of can be detected or measured. In this regard, the desired position of the optical tooling target 354 may represent a condition in which the backing plate 302 is aligned with the reinforcement tooling assembly 480. The position of the optical tooling target 354 can be defined with respect to aircraft coordinates (eg, station, water level, stern line), or in any other suitable reference frame of reference.

During docking of the backing plate 302 to the stiffener tooling assembly 480, one or more laser measuring devices 352 may be activated to monitor the position of the stiffener tooling assembly 480. Based on the deviation or inconsistency between the measured position of the optical tooling target 354 and the desired position, the xy position of the reinforcement tooling assembly 480 is the measured position and the desired position of each optical tooling target 354. It may be adjusted using one or more (not shown) portable trolleys or (not shown) automatic touring vehicles until a gap or inconsistency between them is within a given tolerance. In one embodiment not shown, one or more of the automated guided vehicles are placed under the reinforcement tooling assembly 480 to allow adjustment of the xy position of the reinforcement tooling assembly 480 with respect to the backing plate 302. A sufficient amount may be configured to lift the reinforcement tooling assembly 480 vertically from the floor of the work site. The automatic guided vehicle can then lower the stiffener tooling assembly 480 back into contact with the floor at the work site.

FIG. 23 is a perspective view of the system 300 showing the backing plate 302 and the strongback 370 at the closed position 402 with respect to the reinforcing material tooling assembly 480. As shown above, the system 300 may include one or more posts 452 that may be placed on the outer circumference of the reinforcement tooling assembly 480, such as along one or more sides of the reinforcement tooling assembly 480. One or more of the posts 452 may include one or more linear actuators 456 to support the mass of the strongback 370 at the closed position 402. As shown above, one or more of the hinges 420 may also include one or more linear actuators 456 to support the mass of the strongback 370 in cooperation with the linear actuator 456 of the post 452. In the present disclosure, the linear actuator 456 is linear in the sense that it controls the linear or vertical movement of the strongback 370 from the floating position 404 to the dock position 406 and vice versa. The linear actuator 456 is not limited to actuators that move along a linear direction, such as an actuating cylinder (eg, a hydraulic cylinder 464), but in a linear direction or vertical, such as between a floating position 404 and a dock position 406. An alternative form of actuator configured to move the strongback 370 and the backing plate 302 along the direction may be included. The linear actuator 456 allows the composite skin 152 and the composite stiffener 200 to be moved in contact with each other and to avoid transmitting the mass of the strongback 370 onto the engaged components. , A portion of the offsetting system 450 configured to offset or support at least a portion of the mass of the strongback 370 when the backing plate 302 is docked with the stiffener tooling assembly 480.

In the present disclosure, the closed position 402 is described as a position where the strongback 370 and the backing plate 302 are rotated to a position above the reinforcement assembly tooling 480 or to engage the reinforcement tooling assembly 480. obtain. In this regard, the closed position 402 includes both the floating position 404 and the dock position 406. The floating position 404 can be described as a position in which the backing plate 302 and the composite reinforcing member 200 are vertically spaced from each other. The dock position 406 may be described as the position where the backing plate 302 is engaged with the reinforcing material tooling assembly and / or the composite outer plate 152 is in contact with the composite reinforcing material 200.

FIG. 24 is a side view of the backing plate 302 and the strong back 370 at the closed position 402 (for example, the dock position 406). In the embodiment shown, the backing plate 302 is located above the reinforcement tooling assembly 480. FIG. 24 shows a linear actuator 456 included in each of the hinge 420 and the post 452. Each post 452 may be supported on the floor of the work site or other fixed object (not shown). Each linear actuator 456 may be mounted adjacent to the post 452 or at the top of the post 452. The linear actuator 456 may be configured to extend upward from the post 452 and engage with a plurality of corresponding strongback support fittings 380 that may be included in the strongback 370. For example, the strongback support fitting 376 may be attached to the outer circumference 374 of the strongback along one side of the strongback 370 or the like.

In the embodiments shown, the post 452 may be attached to one side of the reinforcement tooling assembly 480 opposite each of the hinges 420. As shown above, the offset system 450 has a composite skin 152 and composite reinforcement in which substantially or all of the mass of the strongback 370 is sandwiched between the backing plate 302 and the reinforcement tooling 482. It may prevent transmission on the material 200. In this regard, the offsetting system 450 may otherwise impair the integrity of the composite layup and / or cause damage to the backing plate 302, reinforcement tooling 482, and / or bond cart 486, excessive consolidation pressure. Can be prevented from being applied to the composite layup and composite reinforcement 200.

FIG. 25 shows a post 452 with a linear actuator 456 to support at least a portion of the mass of the strongback 370 at the closed position 402 and to vertically lower the strongback 370 from the floating position 404 to the dock position 406. It is a side view of. The post 452 may also include a mechanical stop 458 as a failsafe to support the strongback 370 in the event of one or more failures of the linear actuator 456. In the embodiment shown, the mechanical stop 458 may be configured as a threaded rod 460 that can be screw engaged with the post 452. In the embodiment shown, the threaded rod 460 has an upper end configured to engage a strongback support fitting 380 to prevent the mass of the strongback 370 from being transmitted to the backing plate 302. Can include.

FIG. 26 is a side view of the hinge 420 showing a first rotary actuator 436 and a second rotary actuator 438 for rotating the movable hinge portion 440 of the hinge 420. Also shown is a linear actuator 456 that may be included in the hinge to support the strongback 370 and / or lower the strongback 370 vertically from the plankton position 404 to the dock position 406. In the embodiment shown, the linear actuator 456 engages with the strongback mounting fitting 376 to prevent vertical movement of the strongback 370 when the strongback 370 and backing plate 302 are flipped. Can be stretched to. Further, the lever 462 can be rotated to engage the strongback mounting fitting 376 to assist the linear actuator 456 in hindering the vertical movement of the strongback 370 when inverted. The linear actuator 456 optionally includes a mechanical stop 458 (eg, screw rod 460), which is when the lever 462 is rotated to the unlocked position (eg, see FIG. 40). , The linear actuator 456 may be configured to impede the vertical movement of the strongback 370 in the event of a malfunction.

FIG. 27 shows a strong containing a plurality of linear actuators 456 for supporting the mass of the strongback 370 and for vertically lowering the backing plate 302 from the floating position 404 to the dock position 406 and vice versa. It is the schematic of the back offset system 450. In the embodiment shown, the offset system 450 is a hydraulic cylinder 464 at each of the first, second, third, and fourth hinges 420a, 420b, 420c, 420d located on one side of the strongback 370. (For example, a linear actuator 456) of the first, second, third, and fourth posts 452a, 452b, 452c, 452d located on the other side of the strongback 370 when in the closed position 402. Each includes a corresponding hydraulic cylinder 464 (eg, linear actuator 456). The posts 452a, 452b, 452c, 452d and the hinges 420a, 420b, 420c, 420d each include the first, second, third, and fourth hinge post sets 470a, 470b, 470c, 470d, respectively. ) Two hinge post sets can be formed. The hydraulic cylinders 464 are fluid coupled to a hydraulic controller 468 (eg, via a hydraulic line) and / or (eg, via electrical wiring not shown), which may be configured to control hydraulic pressure in each hydraulic cylinder 464. Can be electrically connected.

In one embodiment, the hydraulic controller 468 may control the oil pressure in each hydraulic cylinder 464 in proportion to the local mass fraction of the strongback 370 in each hydraulic cylinder 464. For example, if the local mass fraction of the strongback 370 in the first hinge postset 470a is analytically determined to be 25% of the total mass of the strongback 370, then the hydraulic system 454 is 25%. The oil pressure of the hydraulic cylinder 464 can be controlled at the first hinge 420a and the first post 452a to support the local mass fraction. The hydraulic controller 468 also in the second, third, and fourth hinge post sets 470b, 470c, 470d according to the local mass fraction of the strongback 370 in each of the hinge post sets 470b, 470c, 470d. The oil pressure can be controlled.

As described above, the hydraulic controller 468 monitors the inconsistency between the current position of the optical tooling target 354 and the desired position of the optical tooling target 354 while the alignment mechanism 350 monitors the floating position 404 (FIG. 39). It may be configured to lower the backing plate 302 vertically from the dock position 406 (see FIG. 40). As shown above, prior to contact between the composite skin 152 and the composite reinforcement 200, the position of the reinforcement tooling assembly 480 is until the backing plate 302 is aligned with the reinforcement tooling assembly 480. , (Not shown) may be adjusted using one or more trolleys or automated guided vehicles.

FIG. 28 shows the rotation of the strongback 370 towards the open position 400 after the backing plate 302 is docked to the reinforcing material tooling assembly 480 and the strongback 370 is disconnected from the backing plate 302. It is a perspective view. Disconnecting the backing plate 302 from the strongback 370, as shown above, releases the clamp arm 336 that connects the strongback 370 to the backing plate 302, as shown in FIGS. 15-16. Can be achieved by

FIG. 29 is a perspective view of the strong back 370 at the open position 400. The strongback 370 may be supported by a hinge 420 on the side of the backing plate 302 and by one or more jack stands 382 (see FIG. 20) on the opposite side of the backing plate 302. The backing plate 302 is docked with the reinforcing material tooling assembly 480 and is shown to sandwich the composite outer plate 152 and the composite reinforcing material 200 between the layup surface 306 of the backing plate 302 and the reinforcing material tooling 482.

FIG. 30 is a perspective view of the backing plate 302 docked with the reinforcing material tooling assembly 480 with the strong back 370 removed. In FIG. 30, the composite outer plate 152 and the composite reinforcing member 200 are both engaged to form a composite assembly. A vacuum bag assembly (not shown) can be attached to the composite assembly in preparation for weight loss and / or co-curing or co-bonding. In this regard, the composite stiffener 200 and the composite skin 152 may be sealed to the backing plate 302 using a bagging film (not shown). The edge of the bagging film may be sealed against the backside 304 of the backing plate 302. A composite assembly that includes a backing plate 302, a stiffener tooling assembly 480, and a bond cart 486 engages the bond cart 486 with one or more carriages (eg, lifts the bond cart 486 with one or more carriages). ) Can be transferred to an oven or autoclave. Consolidation pressure is applied to the bagging film by evacuation 114a and / or weight loss and / or autoclave (not shown) while co-curing and / or co-bonding the composite skin 152 with the composite stiffener 200. Pressure is applied.

FIG. 31 is a schematic exploded view of the composite assembly cut along the blade length direction 154, showing the thickness 166 of the composite outer plate 152 that changes along the blade length direction 154 before weight loss. Flange 206 of the composite stiffener 200, which can be an undulating supplement to the composite skin 152, is also shown. In the embodiment shown, the composite skin 152 has a stacking thickness of 164 at a larger root portion 116 at the tip portion 118 of the composite skin 152. Further, the composite skin 152 is where the stacking thickness 164 can be locally increased within that range to support the increased load from the engine nacelle 112 supported by the wing 114 at that position. The nacelle portion 120 may be included. For example, the wing skin contains approximately 30 composite plies 162 at the tip, approximately 130 composite plies 162 at the root, and a local buildup of approximately 150 or more composite plies 162 at the nacelle portion 120. ) Can be included. As described in more detail below, a change in the wingspan direction at the stack thickness 164 can result in a change in the amount where the stack thickness 164 is reduced during weight loss.

FIG. 32 shows the composite outer plate 152 and the composite reinforcing material 200 sandwiched between the reinforcing material tooling 482 and the backing plate 302 in order to apply a consolidation pressure to the composite outer plate 152 and the composite reinforcing material 200 for weight loss. It is a schematic diagram. As shown above, consolidation pressure is applied to the bagging film by evacuation 114a to seal the composite assembly against the backing plate 302. Additional consolidation pressure can be applied within the autoclave environment. In this regard, consolidation pressure of some or more atmosphere may be applied by the backing plate 302 onto the composite outer plate 152 and the composite reinforcing material 200 supported by the reinforcing material tooling 482.

FIG. 33 is a schematic representation of the assembly of FIG. 32 showing the obedience (eg, out-of-plane flexibility) of the backing plate 302 with the strongback 370 removed from the backing plate. For example, during the application of consolidation pressure to the composite skin 152 and the composite stiffener 200, the stacking thickness 164 can be reduced by approximately 10%. Due to the variation of the stacking thickness 164 along the wingspan direction 154, the backing plate 302 is advantageous during the weight loss process that the stacking thickness 164 is from the pre-weight loss thickness 166 to the post-weight loss thickness. It can be configured to be locally obedient to allow out-of-plane flexibility to accept varying amounts, which can be reduced to 168. In addition, the backing plate 302 may be locally obedient to accept the reduction in stack thickness 164 as a result of the curing shrinkage that may occur during the curing of the thermosetting composite ply 162.

FIG. 34 is a perspective view of the system 300 after the composite assembly is co-cured or co-joined to form a reinforced composite skin panel 150. The backing plate 302 is attached to the strongback 370 and can be vertically raised from the dock position 406 to the floating position 404 and then rotated from the closed position 402 to the open position 400. The hardened and reinforced composite skin 150 can be removed from the reinforced tooling 482 for post-treatment such as inspection.

FIG. 35 is a flowchart comprising one or more steps that may be included in method 500 for manufacturing the reinforced composite skin panel 150. The method may include step 502 to provide a backing plate 302 that includes a layup surface 306 for supporting the composite skin 152. The method may further comprise laying up a plurality of composite plies 162 to form a composite skin 152 on the layup surface 306, as shown in FIG. As shown above, the composite skin 152 was subsequently cured or uncured composite using the removable strongback 370 disclosed herein, as shown in FIG. It can be formed from uncured composite ply 162, which can be combined with stiffeners. However, in some embodiments, the method uses a strongback 370 and a backing plate 302 to harden or uncured composite skin 152 for co-curing or co-bonding. It may include rotating up 200.

Step 504 of the method may include providing a reinforcement tooling assembly 480 (see FIG. 36) having one or more composite reinforcements 200 laid up on the reinforcement tooling 482. In this regard, the method may include laying up a plurality of composite plies 162 to form one or more uncured composite reinforcements 200 on the reinforcement tooling 482. As shown above, in one embodiment, the stiffener tooling 482 may include a plurality of stiffener forming blocks 484, each having a layup of composite ply 162. Reinforcing material forming blocks 484 containing the uncured composite ply 162 are arranged in parallel to form the reinforcing material tooling assembly 480.

Step 506 of the method is during the layup of the composite skin 152 and while rotating the backing plate 302 onto the stationary reinforcement tooling assembly using the plurality of hinges 420 as described above ( (See FIGS. 37-38), it may include detachably connecting a strongback 370 to the backing plate 302 to support the backing plate 302. However, in a further embodiment described above, instead of connecting the strongback 370 to the backing plate 302 in order to rotate it to engage the stationary reinforcing material tooling assembly 480, the method comprises a stationary backing plate 302. It may include connecting the strongback 370 with the reinforcement tooling assembly 480 before rotating the strongback-reinforcing material tooling assembly 480 to engage with. As mentioned above, the method is described herein in the context of rotating the strongback 370 and the backing plate 302 onto a stationary reinforcing material tooling assembly 400, although the structural parts and process steps are each. Almost similar to options.

The method may include detachably fixing the strongback 370 to a backing plate 302 or to a stiffener tooling assembly 480 (see FIG. 36). For example, the method activates one or more clamps 334 attached to the strongback 370 to secure the backside 304 of the backing plate 302 to the strongback 370, as shown in FIGS. 9-16. May include. The clamp 334 (see FIGS. 15-16) may include a clamp arm 336 that may be pneumatically and / or hydraulically actuated. For example, the clamp 334 may include a pneumatic cylinder for operating the clamp arm 336 to secure the socket-type fixture 328 of the backing plate 302 to the ball-type fixture 322 of the strongback 370. The strongback 370 may be connected to the backing plate 302 prior to the layup of the composite skin 152 and before rotating the backing plate 302 to engage the stiffener tooling assembly 480.

The method may further include positioning the strongback 370 on the backing plate 302 or the reinforcement tooling assembly 480 using at least one index mechanism 320 (see, eg, FIGS. 13-14). For example, as shown above, the backing plate 302 has a plurality of socket fixtures 328 (see FIG. 13) for engagement with a corresponding amount of ball fixture 322 (see FIG. 14). Can include. In this regard, the method may include engaging the ball fixture 322 attached to the strongback 370 and the backing plate 302, respectively, with the socket fixture 328 (or vice versa). As shown above, each of the socket type fixtures 328 may include a plate 330 having a socket 332 sized and configured to accept the ball 326. At least one of the ball fixture 322 and / or the socket fixture 328 includes a locking mechanism, such as a clamp 334 for detachably fixing the backing plate 302 to the strongback 370.

Step 508 of the method may include rotating the strongback 370 between the open position 400 (see FIG. 36) and the closed position 402 (see FIG. 38). FIG. 36 is a perspective view of the strong back 370 and the backing plate 302 at the open position 400, and the reinforcing material tooling assembly 480. FIG. 37 shows a strongback 370 and a backing plate oriented approximately vertically at approximately intermediate points during rotation from the open position 400 to the closed position 402 with respect to the reinforcement tooling assembly 480. In one embodiment, the composite skin 152 may be held against the layup surface 306 of the backing plate 302 by molecular attachment and / or by mechanical means. FIG. 38 shows a backing plate 302 and a strong back 370 at the closed position 402. As shown above, the closed position may include a floating position 404 of the backing plate 302 above the reinforcement tooling assembly 480.

FIG. 39 shows the backing plate 302 and the strong back 370 at the floating position 404, and the gap 408 between the composite outer plate 152 and the composite reinforcing member 200. At floating position 404, at least a portion of the mass of the strongback 370 may be supported by one or more linear actuators 456 that may be contained in one or more hinges 420 and / or one or more posts 452. The rotation of the strongback 370 can be facilitated by one or more rotary actuators 434 (see FIG. 26) that can be included in one or more hinges 420 where the strongback 370 can be connected, as described above. For example, the step of rotating the strongback 370 and the backing plate 302 may be included in each of the hinges 420 supporting the strongback 370, a first rotary actuator 436 (see FIG. 26) and a second rotary actuator 438. It may include activating (see FIG. 26).

Step 510 of the method may include moving the composite skin 152 and the composite reinforcement 200 into contact with each other after the backing plate 302 and the reinforcement tooling assembly 480 have been rotated to the floating position 404. The rotary actuator 434 is for the first rotation of the strongback 370 and the backing plate 302 from the open position 400 to the closed position 402, which can be a floating position 404 located a few centimeters or more above the reinforcement tooling assembly 480. Can be activated. As shown in FIG. 39, at the floating position 404, a gap 408 may be present between the composite skin 152 and the composite stiffener 200.

Once in the floating position 404, the mechanical stop 458 or lever 462, which may be included in each hinge 420, is rotated from the locked position (see FIG. 39) to the unlocked position (see FIG. 40) and linear actuator 456 (hydraulic). Under the control of the cylinder 464), it allows vertical movement caused by the gravity of the strongback mounting fitting 376 with respect to the strongback mounting pin 444 and removes the gap 408 between the composite skin 152 and the composite reinforcement 200. Can be done. Further, any mechanical stop 458 that may be included in the hinge 420 and / or post 452 is such that the linear actuator 456 is moved such that the gap 408 is removed and the composite skin 152 is in contact with the composite stiffener 200. Up to, the strongback 370 and the backing plate 302 from the floating position 404 to the dock position 406 may be adjusted to allow vertical movement caused by gravity. The mechanical stop 458, which may be included in the hinge 420 and / or the post 452, is such that if one or more of the linear actuators 456 (hydraulic cylinder 464) of the hinge 420 and / or the post 452 are defective, the mechanical stop 458 In a specific position to support the mass of the strongback 370 against further vertical movement, thereby preventing the weight of the strongback 370 from being transferred to the backing 302 or the stiffener tooling assembly 480. Can be adjusted.

The process of docking the backing plate 302 with the reinforcing material tooling assembly 480 may also use at least one alignment mechanism 350 (see FIGS. 22-23) to align the backing plate 302 with the reinforcing material tooling assembly 480. Can include. In this regard, the step of aligning the backing plate 302 with the reinforcement tooling assembly 480 uses a computer-aided measurement (CAM) device (eg, laser measurement device 352 (see FIGS. 22-23)) as described above. It may include detecting the misalignment of the composite outer plate 152 with the composite reinforcing member 200 based on the position of the hinge shaft 428 as a reference point for the alignment mechanism 350. The method may further include adjusting the xy position of the reinforcement tooling assembly 480 with respect to the backing plate 302 until the composite skin 152 is aligned with the composite reinforcement 200.

As shown above, the adjustment of the xy position of the reinforcement tooling assembly 480 can be placed under the bond cart 486, with a dolly (not shown) or a remotely guided vehicle (not shown). It can be facilitated by use. Upon commanding via remote control or the like, such an automatic carrier lifts the bond cart 486 vertically or z-wise by a small amount (eg, up to a few inches) to measure deviation from the alignment mechanism 350. Based on this, it allows the reinforcement tooling assembly 480 to be positioned in the xy direction until the composite skin 152 is aligned with the composite reinforcement 200. Once the composite skin 152 is aligned with the composite reinforcement 200, the automatic guided vehicle may be instructed to lower the bond cart 486 vertically and lower it back to the floor at the work site.

As mentioned above, step 512 of the method uses the offset system 450 to move the composite skin 152 and the composite stiffener 200 into contact with each other and at least a portion of the mass of the strongback 370. May include offsetting. As shown in FIGS. 39-40, the method vertically lowers the strongback 370 and the backing plate 302 from the floating position 404 to the dock position 406 until the composite skin 152 and the composite stiffener 200 contact each other. Can include. The process of vertically lowering the strongback 370 may include supporting and lowering the strongback 370 with the above-mentioned linear actuator 456 arranged along the outer circumference of the strongback 370.

As shown above, each of the hinges 420 may include a linear actuator 456 (eg, hydraulic cylinder 464). Similarly, each of the posts 452 may include a linear actuator 456. The linear actuator 456 is part of the hydraulic system 454 (see FIG. 27) and is operated independently in cooperation with each other to support the mass of the strongback 370 and dock with the reinforcement tooling assembly 480. , Strong back 370 and backing plate 302 can be lowered. The linear actuator 456 of the offset system 450 is advantageous in that a substantial portion of the mass of the strongback 370 or the entire mass of the strongback 370 is a backing plate 302, a composite outer plate 152, a composite stiffener 200, and / Alternatively, it may prevent transmission to the reinforcing material tooling 482.

The step of offsetting the mass of the strongback 370 may include using a hydraulic controller 468 to control the hydraulic pressure in the hydraulic cylinder 464 (linear actuator 456) during the vertical positioning of the strongback 370. As shown in FIG. 27, the hydraulic cylinder 464 is fluid coupled to and / or controlled by the hydraulic controller 468. The hydraulic controller 468 may control the hydraulic pressure in each hydraulic cylinder 464 so that the hydraulic pressure in each hydraulic cylinder 464 is distributed according to the local mass fraction of the strongback 370 in each hydraulic cylinder 464.

Step 514 of the method may include removing (eg, unlocking) the strongback 370 from the backing plate 302 and rotating the strongback 370 to the open position 400, as shown in FIGS. 41-42. The method uses a bagging film (not shown) sealed against the outer circumference 314 of the backing plate 302 to seal the composite assembly against the backing plate 302, thereby sealing the composite assembly (eg, composite skin). 152 and composite stiffener 200) may further include vacuum bagging (not shown). A vacuum pressure (not shown) is applied to the bagging film to create an atmosphere of at least one or more consolidation pressure (eg, autoclave pressure) on the composite skin 152 and composite reinforcement 200 supported by the reinforcement tooling 482. Add to.

In step 516 of the method, the composite outer plate 152 is co-cured or co-joined with the composite reinforcing material 200 in a state where the backing plate 302 is engaged with the reinforcing material tooling assembly 480 and the strong back 370 is removed from the backing plate 302. May include letting. As shown above, one or more trolleys or automatic guided vehicles (not shown) are assembled to reduce and / or co-cure and / or co-join the composite skin 152 with the composite stiffener 200. (For example, a bond cart, a reinforcing material tooling 482, a composite reinforcing material 200, a composite outer plate 152, and a backing plate 302) can be transferred to an oven or an autoclave.

After co-curing or co-bonding, the assemblies are removed from the oven (not shown) or the autoclave (not shown), such as by using an automatic guided vehicle (not shown), and they open the assembly. Place it adjacent to the strong back at the position. The alignment system 350 may be activated to align the stiffener tooling assembly with the hinge shaft 428 of the hinge 420 where the backing plate 302 is mounted. The rotary actuator 434 (eg, first and second rotary actuators 436, 438) can be activated to rotate the strongback 370 (see FIG. 21) from the open position 400 to the floating position 404. The linear actuator 456 of the hinge 420 and the post 452 can support the mass of the strongback 370 while being controlled by the hydraulic system 454 and vertically lowered to engage the strongback 370 with the backing plate 302.

The index mechanism 320 (see FIGS. 13-14) can facilitate alignment with the strongback backing plate, such as by using the ball fixture 322 and the corresponding socket fixture 328 described above. Once the strongback 370 is engaged with the backing plate 302, one or more of the clamp arms 336 (see FIGS. 15-16) can be activated to secure the backing plate 302 to the strongback 370. After fixing the backing plate 302 to the strongback 370, the assembly can be lifted vertically to the floating position 404, for example by using a linear actuator 456. The hinge rotary actuator 434 is then activated, at which time the strongback 370 and the backing plate 302 are rotated to the open position 400 and supported on the stiffener tooling 482 for post-treatment such as inspection, hardening. Reinforced composite skin panel 150 is left.

In addition, the disclosure includes embodiments under the following provisions.
Clause 1
A system for manufacturing reinforced composite skin panels
Reinforcement tooling assembly, including reinforcement tooling configured to support multiple composite reinforcements,
A backing plate with a layup surface for laying up composite skins,
A strong back that is detachably connected to one of the backing plate and the reinforcing material tooling assembly, and a plurality of hinges, each having a fixed hinge portion and a movable hinge portion, wherein the reinforcing material of the backing plate. A plurality of movable hinge portions connected to one of the strongback and the stiffener touring assembly so as to rotate between an open position and a closed position for engagement with the touring assembly. A system with hinges.
Clause 2
The system according to Clause 1, further comprising an offsetting system configured to offset at least a portion of the mass of the strongback when the composite skin and the composite stiffener are moved into contact with each other.
Clause 3
The offset system comprises a plurality of linear actuators arranged along the strongback perimeter of the strongback.
The linear actuator is configured to vertically move the strongback and one of the backing plate and the reinforcing material tooling assembly between the floating position and the dock position, and the composite outer plate and the said. The system according to clause 2, wherein the composite reinforcements come into contact with each other at the dock position.
Clause 4
The offset system
Including a plurality of posts arranged along the outer circumference of the strong back of the strong back.
The system according to clause 3, wherein one or more of the posts include a linear actuator.
Clause 5
The system according to Clause 3, wherein the linear actuator is configured as a plurality of hydraulic cylinders fluidly coupled to a hydraulic controller configured to control the hydraulic pressure in each hydraulic cylinder.
Clause 6
The system of Clause 1, further comprising one or more rotary actuators attached to at least one of the hinges and configured to rotate one of the strongback and the stiffener tooling assembly.
Clause 7
The system according to clause 1, further comprising at least one index mechanism configured to position the strongback on one of the backing plate and the reinforcing material tooling assembly.
Clause 8
9. The system of clause 7, wherein the indexing mechanism comprises a ball-type fixture and a socket-type fixture attached to the strongback and one of the backing plate and the reinforcement tooling assembly.
Clause 9
The system of Clause 1, further comprising a plurality of clamps attached to the strongback and configured to detachably secure the strongback to one of the backing plate and the stiffener tooling assembly.
Clause 10
The system of Clause 1, further comprising at least one alignment mechanism configured to align the backing plate with the reinforcement tooling assembly and vice versa.
Clause 10.5
Clause 1 further comprises at least one alignment mechanism configured to align the backing plate with the reinforcing material tooling assembly or to align the reinforcing material tooling assembly with the backing plate. The system described in.
Clause 11
A system for manufacturing reinforced composite skin panels
Reinforcement tooling assembly, including reinforcement tooling configured to support multiple composite reinforcements,
A backing plate with a layup surface to support the composite skin,
Strong back, detachably connected to the backing plate,
A plurality of hinges, each having a linear actuator, a fixed hinge portion, and a movable hinge portion, wherein the fixed hinge portion is connected to a fixed object for engagement of the backing plate with the reinforcing material tooling assembly. A plurality of hinges, wherein the movable hinge portion is connected to the strong back so that the strong back rotates between the open position and the closed position.
A plurality of linear actuators arranged on one or more sides of the strongback when in the closed position.
A system in which the linear actuators work together to vertically lower the strongback and the backing plate from a floating position to a dock position where the composite skin is in contact with the composite reinforcement.
Clause 12
A method for manufacturing reinforced composite skin panels,
To provide a backing plate containing a layup surface that supports a composite skin,
To provide a composite reinforcement assembly containing one or more composite reinforcements laid up on a reinforcement tooling,
A plurality of hinges, each having a fixed hinge portion and a movable hinge portion, are used to detachably connect the strong back to one of the backing plate and the reinforcing material tooling assembly, wherein the fixed hinge portion. Is connected to a fixed object, the movable hinge portion is connected to the strong back, is connected, and the composite outer plate is engaged with the composite reinforcing material to form a reinforced composite outer panel. A method comprising rotating the strongback coupled to one of the backing plate and the stiffener tooling assembly from an open position to a closed position.
Clause 13
After engaging the composite outer plate with the composite reinforcing material, the strong back is removed from one of the backing plate and the reinforcing material tooling assembly, and the strong back is rotated toward the open position. The method of clause 12, further comprising.
Clause 14
12. The method of Clause 12, further comprising offsetting at least a portion of the mass of the strongback using an offset system when the composite skin and the composite stiffener are moved into contact with each other. ..
Clause 15
The step of offsetting the strong back is
Clause 14 comprising vertically lowering the strongback and one of the backing plate and the reinforcing material tooling assembly from a floating position to a dock position until the composite skin comes into contact with the composite reinforcing material. The method described in.
Clause 16
The step of lowering the strong back vertically is
25. The method of clause 15, comprising supporting and lowering the strongback using one or more linear actuators arranged along the perimeter of the strongback.
Clause 17
The linear actuator is a hydraulic cylinder, and the step of offsetting the mass of the strongback is
16. The method of clause 16, wherein a hydraulic controller is used to control the hydraulic pressure in the hydraulic cylinders so that the hydraulic pressure in each hydraulic cylinder is distributed according to the local mass fraction of the strongback. ..
Clause 18
Further comprising aligning the backing plate with the reinforcement tooling assembly using at least one alignment mechanism when the composite skin and the composite stiffener are moved into contact with each other. The method described in Clause 12.
Clause 19
The step of rotating the strongback connected to one of the backing plate and the reinforcing material tooling assembly is
Clause 12 comprises using the first rotary actuator and the second rotary actuator of the hinge to rotate the strongback coupled to one of the backing plate and the stiffener tooling assembly. the method of.
Clause 20
A step of detachably connecting the strong back to one of the backing plate and the reinforcing material tooling assembly
12. The method of clause 12, wherein a plurality of clamps are used to detachably secure the strongback to one of the backing plate and the reinforcing material tooling assembly.
Clause 21
12. The method of clause 12, further comprising positioning the strongback on one of the backing plate and the reinforcing material tooling assembly using at least one indexing mechanism.
Clause 22
A step of positioning the strongback on one of the backing plate and the reinforcing material tooling assembly
Clause 21 includes engaging a ball-type fixture, respectively, attached to one of the strongback and the backing plate and the reinforcement tooling assembly with a socket-type fixture, and vice versa. The method described.
Clause 22.5
A step of positioning the strongback on one of the backing plate and the reinforcing material tooling assembly
Engaging a ball-type fixture attached to one of the strongback and the backing plate and the reinforcing material tooling assembly with the socket-type fixture, or with the strongback and the backing plate. 21. The method of clause 21, comprising engaging a socket type fixture, each attached to one of the stiffener tooling assemblies, with a ball type fixture.

Further amendments and improvements to this disclosure will be apparent to those skilled in the art. Accordingly, the particular combination of parts described and illustrated herein is intended to represent only a particular embodiment of the present disclosure and is an alternative practice within the spirit and scope of the present disclosure. It is not intended to serve as a limiting example.

Claims (15)

A system (300) for manufacturing a reinforced composite skin panel (150).
Reinforcing material tooling assembly (480), including reinforcement tooling (482) configured to support a plurality of composite reinforcing materials (200),
A backing plate (302) having a layup surface (306) for laying up the composite outer plate (152),
A strong back (370) that is detachably connected to one of the backing plate (302) and the reinforcing material tooling assembly (480), and a fixed hinge portion (430) and a movable hinge portion (440), respectively. A plurality of hinges (420) having a rotation between the open position (400) and the closed position (402) due to the engagement of the backing plate (302) with the reinforcing material tooling assembly (480). A system (300) comprising a plurality of hinges (420) to which the movable hinge portion (440) is connected to one of the strongback (370) and the reinforcement tooling assembly (480). ). An offset system (450) configured to equilibrate at least a portion of the mass of the strongback (370) as the composite skin (152) and the composite reinforcement (200) are moved into contact with each other. The system (300) according to claim 1, further comprising). The offset system (450) includes a plurality of linear actuators (456) arranged along the strongback circumference (374) of the strongback (370).
The linear actuator (456) is located between the floating position (404) and the dock position (406) among the strong back (370) and the backing plate (302) and the reinforcing material tooling assembly (480). The system (300) of claim 2, wherein one is configured to move vertically and the composite skin (152) and the composite reinforcement (200) are in contact with each other at the dock position (406). The offset system (450)
A plurality of posts (452) arranged along the strong back outer circumference (374) of the strong back (370) are included.
The system (300) of claim 3, wherein one or more of the posts (452) include a linear actuator (456). One or more rotary actuators (434) attached to at least one of the hinges (420) and configured to rotate one of the strongback (370) and the stiffener tooling assembly (480). The system (300) according to any one of claims 1 to 4, further comprising. Claim that one of the backing plate (302) and the reinforcing material tooling assembly (480) is further provided with at least one index mechanism (320) configured to position the strongback (370). The system (300) according to any one of 1 to 5. The index mechanism (320) is attached to one of the strong back (370), the backing plate (302) and the reinforcing material tooling assembly (480), and is a ball type fixture (322) and a socket type. The system (300) according to claim 6, comprising a fixture (328). A method for manufacturing a reinforced composite skin panel (150).
To provide a backing plate (302) that includes a layup surface (306) that supports the composite skin (152).
To provide a composite stiffener (200) assembly comprising one or more composite stiffeners (200) laid up on a stiffener tooling (482).
Use multiple hinge (420), to one of said backing plate (302) and the stiffener tooling assembly (480), thereby removably coupled to strong back (370), wherein said plurality Each of the hinges (420) has a fixed hinge portion (430) connected to a fixed object (424) and a movable hinge portion (440) connected to the strongback (370), and the composite outer. From the open position (400) to the closed position (402) in order to engage the plate (152) with the composite reinforcing material (200) to form a reinforced composite outer panel (150), the backing plate ( A method comprising rotating the strongback (370) coupled to one of 302) and the stiffener tooling assembly (480). After engaging the composite outer plate (152) with the composite reinforcing material (200), the strong back (370) is attached from one of the backing plate (302) and the reinforcing material tooling assembly (480). 8. The method of claim 8, further comprising removing and rotating the strongback (370) towards the open position (400). The offset system (450) is used to equilibrate at least a portion of the mass of the strongback (370) as the composite skin (152) and the composite reinforcement (200) are moved into contact with each other. The method of claim 8 or 9, further comprising causing . The step of equilibrating at least a part of the mass of the strongback (370) is
From the floating position (404) to the dock position (406), the strong back (370), and the backing plate (302) and the reinforcement until the composite outer plate (152) comes into contact with the composite reinforcing material (200). 10. The method of claim 10, comprising vertically lowering one of the material tooling assemblies (480). The step of vertically lowering the strong back (370) is
11. The claim 11 comprises supporting and lowering the strongback (370) by using one or more linear actuators (456) arranged along the outer circumference (374) of the strongback (370). the method of. When the composite outer plate (152) and the composite reinforcing material (200) are moved so as to come into contact with each other, at least one alignment mechanism (350) is used to reinforce the backing plate (302). The method of any one of claims 8-12, further comprising aligning with the material tooling assembly (480). The step of rotating the strong back (370) connected to one of the backing plate (302) and the reinforcing material tooling assembly (480) is
A first rotary actuator (436) and a second rotary actuator (438) of the hinge (420) are used to be connected to one of the backing plate (302) and the reinforcing material tooling assembly (480). The method according to any one of claims 8 to 13, which comprises rotating the strong back (370). A claim further comprising positioning the strongback (370) on one of the backing plate (302) and the reinforcing material tooling assembly (480) using at least one index mechanism (320). The method according to any one of 8 to 14.

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